Mitsubishi 4D68 - Manual

4D68 ENGINE (E - W) - Specifications 11A-1-1 1. SPECIFICATIONS SERVICE SPECIFICATIONS Item Standard value Limit Drive belt and glow plug Glow plug resistance W 0.5 - Timing belt Timing belt deflection mm 4.0 - 5.0 - Timing belt “B” deflection mm 5.0 - 7.0 - Rocker arms, rocker shaft and camshaft Cam...

4D68 ENGINE (E - W) - Specifications 11A-1-2 Item Limit Standard value Oil cooler by-pass valve dimension (L) [by-pass hole closing temperature (97 - 103 ° C or more)] mm 40.0 - Oil pump side clearance Drive gear 0.08 - 0.14 - Driven gear 0.06 - 0.12 - Pistons and connecting rods Piston O.D. mm 82.7...

4D68 ENGINE (E - W) - Specifications 11A-1-3 REWORK DIMENSIONS Item Standard value Limit Cylinder head, valves and valve springs Cylinder head oversize valve guide hole 0.05 O.S. 13.050 - 13.068 - (both intake and exhaust) mm 0.25 O.S. 13.250 - 13.268 - 0.50 O.S. 13.500 - 13.518 - Cylinder head over...

4D68 ENGINE (E - W) - Specifications 11A-1-4 TORQUE SPECIFICATIONS Items Nm Drive belt and glow plug Oil level gauge guide bolt 13 Pulley bolt (for power steering pump drive) 9 Alternator brace bolt 23 Lock bolt 23 Adjusting bolt 10 Alternator pivot nut 44 Crankshaft pulley bolt 25 Glow plug 18 Glow...

4D68 ENGINE (E - W) - Specifications 11A-1-5 Items Nm Injection nozzle 54 Fuel injection pump bracket nut 23 Intake and exhaust manifold Air temperature sensor 14 Air intake fitting bolt 17 EGR valve bolt 24 EGR pipe bolt and nut 17 Turbocharger heat protector bolt M8 13 M6 11 Exhaust fitting heat p...

4D68 ENGINE (E - W) - Specifications 11A-1-7 NEW TIGHTENING METHOD - BY USE OF BOLTS TO BE TIGHTENED IN PLASTIC AREA A new type of bolts, to be tightened in plastic area, is currently used some parts of the engine. The tightening method for the bolts is different from the conventional one. Be sure t...

4D68 ENGINE (E - W) - Specifications 11A-1-8 FORM-IN-PLACE GASKET The engine has several areas where the form-in-place gasket (FIPG) is in use. To ensure that the gasket fully serves its purpose, it is necessary to observe some precautions when applying the gasket. Bead size, continuity and location...

4D68 ENGINE (E - W) - Special Tools 11A-2-1 2. SPECIAL TOOLS Tool Number Name Use MB990767 End yoke holder Holding camshaft sprocket or fuel injection pump when loosening or tightening bolts. Use with MD998719 MB991603 Bearing installer stopper A guide for removal and installation of counterbalance ...

4D68 ENGINE (E - W) - Drive Belt and Glow Plug 11A-3-1 3. DRIVE BELT AND GLOW PLUG REMOVAL AND INSTALLATION DEN0885 1 2 3 4 5 6 7 8 9 10 11 12 13 Nm 18 Nm 1.8 Nm 44 Nm 10 Nm 23 Nm 9 Nm 25 Nm Removal steps 1. Oil level gauge 2. O-ring 3. Oil level gauge guide 4. O-ring 5. Drive belt (V-type) 6. Pulle...

4D68 ENGINE (E - W) - Drive Belt and Glow Plug 11A-3-2 REMOVAL SERVICE POINTS A A " GLOW PLUG REMOVAL (1) When removing the glow plug, you may loosen using a tool up to the point where one or more threads are left in engagement. Beyond this point, loosen with fingers. Caution D Do not reuse a gl...

4D68 ENGINE (E - W) - Timing Belt 11A-4-1 4. TIMING BELT REMOVAL AND INSTALLATION DEN0886 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 11 Nm 45 Nm 18 Nm 11 Nm 11 Nm 9 Nm 9 Nm 9 Nm 49 Nm 48 Nm 48 Nm 83 Nm 88 Nm 54 Nm 118 Nm 13 Nm 28 Removal steps 1. Timing belt front upper ...

4D68 ENGINE (E - W) - Timing Belt 11A-4-5 (3) Make sure that the pulley center and the bolt center are located as shown in the illustration. (4) More the tensioner “B” in the direction of arrow while lifting with a finger to give a sufficient tension to the tension side of the timing belt. In this c...

4D68 ENGINE (E - W) - Timing Belt 11A-4-8 INSPECTION TIMING BELTS The timing belts must be checked closely. Should the following defects be evident, replace the belt with a new one.(1) Hardened back surface rubber Glossy, non-elastic, and so hard that no mark is produced even when scratched by finge...

4D68 ENGINE (E - W) - Glow Plug, Fuel Injection Pump And Injection Nozzle 11A-5-1 5. GLOW PLUG, FUEL INJECTION PUMP AND INJECTION NOZZLE REMOVAL AND INSTALLATION DEN0887 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 18 Nm 18 Nm 13 Nm 13 Nm 23 Nm 23 Nm 35 Nm 54 Nm 29 Nm 29 Nm 29 Nm 5 Nm 5 Nm Remova...

4D68 ENGINE (E - W) - Glow Plug, Fuel Injection Pump And Injection Nozzle 11A-5-3 INSTALLATION SERVICE POINTS " A A NOZZLE GASKET / HOLDER GASKET INSTALLATION (1) Clean nozzle holder installation areas of the cylinder head. (2) Fit a new nozzle gasket and holder gasket into the nozzle holder hol...

4D68 ENGINE (E - W) - Intake and Exhaust Manifolds 11A-6-1 6. INTAKE AND EXHAUST MANIFOLDS REMOVAL AND INSTALLATION DEN0888 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 19 20 21 22 26 27 28 29 30 23 18 32 36 35 34 37 31 33 39 38 17 Nm 17 Nm 17 Nm 11 Nm 11 Nm 14 Nm 13 Nm 13 Nm 13 Nm 13 Nm 14 Nm 10 Nm 10...

4D68 ENGINE (E - W) - Intake and Exhaust Manifolds 11A-6-2 INSTALLATION SERVICE POINTS " A A OIL RETURN PIPE GASKET INSTALLATION (1) Install the oil return pipe gasket in such a way that its projection is located at the illustrated position. " B A EYEBOLT INSTALLATION (1) Before installing t...

4D68 ENGINE (E - W) - Water Pump, Thermostat, Hose and Pipes 11A-7-2 INSTALLATION SERVICE POINTS " A A THERMOSTAT HOUSING INSTALLATION (1) Apply a 3 mm bead of form-in-place gasket (FIPG) to the mounting surface. Specified sealant: Mitsubishi Genuine Part No. MD970389 or equivalent. " B A WA...

4D68 ENGINE (E - W) - Rocker Arms, Rocker Shaft and Camshaft 11A-8-1 8. ROCKER ARMS, ROCKER SHAFT AND CAMSHAFT REMOVAL AND INSTALLATION DEN0891 1 2 3 4 5 6 7 8 9 10 11 12 13 29 Nm 29 Nm 20 Nm 20 Nm 15 Nm 6 Nm 29 Nm 12 12 12 Apply engine oil to all moving parts before installation. Removal steps 1. B...

4D68 ENGINE (E - W) - Rocker Arms, Rocker Shaft and Camshaft 11A-8-3 VALVE CLEARANCE ADJUSTMENT (1) Turn the crankshaft clockwise and align the timing mark on camshaft sprocket with that on the injection pump bracket. (2) Adjust the valve clearance at the points shown in the illustration. (3) Loosen...

4D68 ENGINE (E - W) - Cylinder Head, Valves and Valve Springs 11A-9-1 9. CYLINDER HEAD, VALVES AND VALVE SPRINGS REMOVAL AND INSTALLATION DEN0777 Apply engine oil to all moving parts before installation. Removal steps A A " " E A 1. Cylinder head bolt 2. Cylinder head assembly " D A 3. C...

4D68 ENGINE (E - W) - Cylinder Head, Valves and Valve Springs 11A-9-2 REMOVAL SERVICE POINTS A A " CYLINDER HEAD BOLT REMOVAL (1) Using a 12 mm - 12 points socket wrench, loosen the cylinder head bolts. A B " RETAINER LOCK REMOVAL (1) Store removed valves, springs and other parts, tagged to ...

4D68 ENGINE (E - W) - Cylinder Head, Valves and Valve Springs 11A-9-3 " C A RETAINER LOCK INSTALLATION (1) The valve spring, if excessively compressed, causes the bottom end of the retainer to be in contact with, and damage, the stem seal. " D A CYLINDER HEAD GASKET INSTALLATION (1) In case ...

4D68 ENGINE (E - W) - Cylinder Head, Valves and Valve Springs 11A-9-6 (2) Install the valve and, while pressing the valve against the valve seat, measure the valve stem projection between the valve stem end and the valve spring seat seating surface. Standard value: 43.45 mm Limit: 43.95 mm VALVE SEA...

4D68 ENGINE (E - W) - Cylinder Head, Valves and Valve Springs 11A-9-7 VALVE GUIDE REPLACEMENT PROCEDURE (1) Using the special tool and a press, remove the valve guide toward the cylinder head gasket surface. (2) Rebore the valve guide hole to the new oversize valve guide outside diameter. Valve guid...

4D68 ENGINE (E - W) - Front Case, Counterbalance Shafts and Oil Pan 11A-10-1 10. FRONT CASE, COUNTERBALANCE SHAFTS AND OIL PAN REMOVAL AND INSTALLATION DEN0892 5 1 3 4 6 7 11 12 13 14 15 16 17 31 19 20 21 22 23 24 25 26 27 28 29 30 10 2 8 9 18 24 Nm 10 Nm 54 Nm 18 Nm 44 Nm 23 Nm 36 Nm 24 Nm 16 Nm 10...

4D68 ENGINE (E - W) - Front Case, Counterbalance Shafts and Oil Pan 11A-10-2 REMOVAL SERVICE POINTS A A " OIL PAN REMOVAL (1) Knock the special tool deeply between the oil pan and the cylinder block. (2) Hitting the side of the special tool, slide the special tool along the oil pan to remove it....

4D68 ENGINE (E - W) - Front Case, Counterbalance Shafts and Oil Pan 11A-10-4 (4) Insert the installer aligning with the guide pin and install the bearing. " C A COUNTERBALANCE SHAFT FRONT BEARING INSTALLATION (1) Remove the rear bearing installing portion from the special tool. (2) Install the g...

4D68 ENGINE (E - W) - Front Case, Counterbalance Shafts and Oil Pan 11A-10-5 (5) Insert the installer aligning with the guide pin and install the bearing. " D A OIL PUMP OIL SEAL INSTALLATION " E A COUNTERBALANCE SHAFT OIL SEAL INSTALLATION " F A CRANKSHAFT FRONT OIL SEAL INSTALLATION (1...

4D68 ENGINE (E - W) - Front Case, Counterbalance Shafts and Oil Pan 11A-10-6 " G A OIL PUMP DRIVEN GEAR / OIL PUMP DRIVE GEAR INSTALLATION (1) Apply engine oil amply to the gears and line up the alignment marks. " H A FRONT CASE INSTALLATION (1) Install the special tool at the front end of t...

4D68 ENGINE (E - W) - Pistons and Connecting Rods 11A-11-1 11. PISTONS AND CONNECTING RODS REMOVAL AND INSTALLATION DEN0771 Apply engine oil to all moving parts before installation. Removal steps " F A 1. Connecting rod cap nut A A " " E A 2. Connecting rod cap " C A 3. Connecting ro...

4D68 ENGINE (E - W) - Pistons and Connecting Rods 11A-11-2 REMOVAL SERVICE POINTS A A " CONNECTING ROD CAP REMOVAL (1) Mark the cylinder number on the side of the connecting rod big end for correct reassembly. INSTALLATION SERVICE POINTS " A A PISTON PIN / PISTON / CONNECTING ROD INSTALLATIO...

4D68 ENGINE (E - W) - Pistons and Connecting Rods 11A-11-3 " D A PISTON AND CONNECTING ROD ASSEMBLY INSTALLATION (1) Liberally coat engine oil on the circumference of the piston, piston ring, and oil ring. (2) Arrange the piston ring and oil ring gaps as shown in the illustration. (3) Rotate the...

4D68 ENGINE (E - W) - Pistons and Connecting Rods 11A-11-5 INSPECTION PISTON RING (1) Check for side clearance. If the limit is exceeded, replace the ring or piston, or both. (2) In the case of semi-keystone type piston rings, check the ring to ring groove clearance as illustrated. Standard value: N...

4D68 ENGINE (E - W) - Pistons and Connecting Rods 11A-11-6 CONNECTING ROD BUSHING REPLACEMENT (1) Using the special tool, remove the bushing. (2) Using the special tool, install the bushing, aligning the oil hole of the bushing with the oil hole at the small end of the connecting rod. (3) Finish the...

4D68 ENGINE (E - W) - Crankshaft, Cylinder Block and Flywheel 11A-12-1 12. CRANKSHAFT, CYLINDER BLOCK AND FLYWHEEL REMOVAL AND INSTALLATION DEN0893 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 “A” 11 Nm 32 Nm 132 Nm 11 Nm Apply engine oil to all moving parts before installation. Removal steps 1. Fly...

4D68 ENGINE (E - W) - Crankshaft, Cylinder Block and Flywheel 11A-12-2 INSTALLATION SERVICE POINTS " A A CRANKSHAFT BEARING INSTALLATION When the bearing needs replacing, select and install a proper bearing by the following procedure. (1) Measure the crankshaft journal diameter and confirm its c...

4D68 ENGINE (E - W) - Crankshaft, Cylinder Block and Flywheel 11A-12-4 " C A OIL SEAL INSTALLATION " D A OIL SEAL CASE INSTALLATION Specified sealant: Mitsubishi Genuine Part No. MD970389 or equivalent INSPECTION CRANKSHAFT OIL CLEARANCE (PLASTIC GAUGE METHOD) (1) Remove oil from the cranksh...

4D68 ENGINE (E - W) - Crankshaft, Cylinder Block and Flywheel 11A-12-5 CYLINDER BLOCK (1) Visually check for cracks, rust, and corrosion, and inspect the cylinder block using a flaw detecting agent. Rectify defects where possible or replace the cylinder block. (2) Check the cylinder block’s top surf...

4D68 ENGINE (E - W) - Crankshaft, Cylinder Block and Flywheel 11A-12-6 (4) Bore all cylinders to the calculated boring finish dimension. Caution To prevent distortion that may result from temperature rise during honing, bore cylinders, in the order of No. 2, No. 4, No. 1 and No. 3. (5) Hone to the f...